TM 11-6625-2965-14&P TECHNICAL MANUAL OPERATOR’S ORGANIZATIONAL DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL [INCLUDING REPAIR PARTS AND SPECIAL TOOLS LISTS] POWER SUPPLY PP-7548/U (HEWLETT-PACKARD MODEL 6205B] [NSN 6625-00-437-4861] HEADQUARTERS, DEPARTMENT OF THE ARMY 25 FEBRUARY 1980
WARNING HIGH VOLTAGE is used during the performance of maintenance as instructed in this manual. DEATH ON CONTACT may result if personnel fail to observe safety precautions. DO NOT ATTEMPT to make internal connections or perform adjustments unless another person, capable of performing first aid, is present. For electric shock protection, use only extension cord and power receptacles with a safety-ground connector, or otherwise connect the chassis to a safety ground.
TM 11-6625-2965-14&P This manual contains copyright material reproduced by permission of Hewlett-Packard Company T ECHNICAL M A N U A L HEADQUARTERS DEPARTMENT OF THE ARMY WASHINGTON, DC, 25 February 1980 No.
TM 11-6625-2965-14&P TABLE OF CONTENTS Section O INSTRUCTIONS . . . . . . . . . . . . . . . 0-l Scope 0-2 Indexes of Publications 0-3 Maintenance Forms, Records and Reports 0-4 Reporting Equipment Improvement Recommendations (EIR) 0-5 Administrative Storage 0-6 Destruction of Army Electronics Materiel I Section Page No. 3-38 Special Operating Considerations 3-39 Pulse Loading 3-41 Output Capacitance 3-43 Reverse Voltage Loading 3-45 Reverse Current Loading .
TM 11-6625-2965-14&P LIST OF ILLUSTRATIONS Figure 2-1 2-2 2-3 2-4 3-1 3-2 3-3 3-4 3-5 3-6 3-7 3-8 3-9 3-10 4-1 Page No.
TM 11-6625-2965-14&P SECTION O INSTRUCTIONS 0-1. SCOPE This manual applies directly to Power Supply PP-7548/U (Hewlett-Packard Model 6205) having serial prefix number 7L2301 and up. For serial prefixes below 7L2301 refer to Appendix E. For serials above 7L4450 check for inclusion of change page. 0-2. INDEXES OF PUBLICATIONS a. DA Pam 310-4. Refer to the latest issue of DA Pam 310-4 to determine whether there are new editions , changes, or additional publications pertaining to the equipment. b.
TM 11-6625-2965-14&P 1-1 D E S C R I P T I O N may be programmed from a remote location by means of an external voltage source or resistance. b. Remote Sensing. The degradation in regulation which would occur at the load because of the voltage drop which takes place in the load leads can be reduced by using the power supply in the remote sensing mode of operation. c.
TM 11-6625-2965-14P trip voltage is exceeded. When Option 11 is requested by the customer the device is connected at the factory. 14523A Trip Voltage Range: 2.5 to 44 Volts, screwdriver adjustable. 1-12 INSTRUMENT AND SERVICE MANUAL IDENTIFICATION Detailed coverage of Option 11 is included in Appendix A at the rear of manuals that support power supplies containing Option 11.
Table 1-1. Specifications TM 11-6625-2965-14&P INPUT: l15Vac ±10%, single phase, 48-440 Hz. 0-50 or 0-5 Volt voltmeter or as a 0-0.75 or 0.075 Amp ammeter. OUTPUT: Two independent outputs, each of which can be set at either 0-40 Volts @ 0.3 Amp or 0-20 Volts @ 0.6 Amp. OUTPUT CONTROLS: RANGE switches select desired operating mode for each section and coarse and fine VOLTAGE controls set desired output voltages.
TM 11-6625-2965-14&P SECTION II INSTALLATION 2-1 INITIAL INSPECTION 2-2 Before shipment, this instrument was inspected and found to be free of mechanical and electrical defects. As soon as the instrument is unpacked, inspect for any damage that may have occurred in transit. Save all packing materials until the inspection is completed. If damage is found, a claim should be filed with the carrier. Hewlett-Packard Sales and Service office should be notified.
TM 11-6625-2965-14&P Figure 2-2. Figure 2-3.
TM 11-6625-2965-14&P spacing panels. Angle brackets are placed behind combining straps as shown in Figure 2-3. b. Remove four screws from front panel of unit. c. Slide combining strips between front panel and case of unit. d. Bolt angle brackets to front sides of case and replace front panel screws. 2-17 INPUT POWER REQUIREMENTS 2-18 This power supply may be operated from either a nominal 115 Volt or 230 Volt 48-440 Hertz power source. The unit, as shipped from the factory, is wired for 115 Volt operation.
TM 11-6625-2965-14&P SECTION Ill OPERATING INSTRUCTIONS erational capabilities of the supply. A more theoretical description concerning these operational features is contained in Application Note 90 and in various Tech Letters. Copies of these can be obtained from your local Hewlett-Packard field office, 3-1 TURN-ON CHECKOUT PROCEDURE 3-5 NORMAL OPERATING MODE Figure 3-1.
TM 11-6625-2965-14&P 3-13 If load considerations require that the output power distribution terminals be remotely located from the power supply, then the power supply output terminals should be connected to the remote distribution terminals via a pair of twisted or shielded wires and each load separately connected to the remote distribution termina1s. For this case, remote sensing should be used (Paragraph 3-25).
TM 11-6625-2965-14&P A7 A6 A8 A10+S + GND - programming mately 1000 specifications tained. The programmed –S voltage source should be approxiohms if the temperature and stability of the power supply are to be mainprogramming accuracy is 1% of the voltage. 3-24 Methods of voltage programming with gain are discussed in Application Note 90, Power Supply Handbook; available at no charge from your local Sales Office. PROGRAMMING RESISTOR Figure 3-4.
TM 11-6625-2965-14&P ages of the individual supplies. Each of the individual supplies must be adjusted in order to obtain the total output voltage. The power supply contains a protective diode connected internally across the output which protects the supply if one power supply is turned off while its series partner(s) is on. tracts directly from the available output voltage and also reduces the amplitude of the feedback error signals that are developed within the unit.
TM 11-6625-2965-14&P determined by its voltage control setting. units are effective and the current limit for the entire configuration is equal to the lowest current limit setting. If any of the settings are too low, automatic crossover to current limiting operation will occur and the output voltage will drop. Remote sensing and programming can be used; however, the strapping arrangements shown in the applicable figures show local sensing and programming. 3-34 Auto-Parallel.
TM 11-6625-2965-14&P not desired, set the preset limit for the peak requirement and not the average. 3-35 AUTO-TRACKING OPERATION (See Figure 3-10) 3-36 The Auto-Tracking configuration is used when it is necessary that several different voltages referred to a common bus, vary in proportion to the setting of a particular instrument (the control or master). A fraction of the master’s output voltage is fed to the comparison amplifier of the slave supply, thus controlling the slave’s output.
TM 1 I-6625-2965-14&P SECTION IV PRINCIPLES OF OPERATION REFERENCE REGULATOR CIRCUIT t AC INPuT BIAS SUPPLY POWER TRANSFORMER CURRENT LIMITING CIRCUIT B IA S v VOLTAGES 4 * P/o 2 I ~o Pm RANGE SWITCH (s2) RECTIFIER AND FILTER SERIES REGULATOR CURRENT sAMPLING RESISTORS A NOTE — D E N O T E S V O L T A G E FEEOBACK PATH — D E N O T E S C U R R E N T LIMIT PATH CONSTANT VOLTAGE INPUT CIRCUIT DRIVER 4 4 4 AMPL + 4 CIRCUIT 4 1, Figure 4-1.
TM 11-6625-2965-14&P series regulator so that the output current is limited to the proper value. ponents). Transistor Q1 consists of two transistors housed in a single package. The transistors have matched characteristics minimizing differential voltages due to mismatched stages. Moreover, drift due to thermal differentials is minimized, since both transistors operate at essentially the same temperature.
TM 11-6625-2965-14&P 4-28 The reference circuit consists of series regulating transistor Q9 and error amplifier Q8. Output voltage changes are detected by Q8 whose base is connected to the junction of a voltage divider (R41, R42) connected directly across the supply. Any error signals are amplified and inverted by Q8 and applied to the base of series transistor Q9.
TM 11-6625-2965-14&P Figure 4-2.
TM 11-6625-2965-14&P SECTION V MAINTENANCE 5-1 INTRODUCTION 5-2 Upon receipt of the power supply, the performance check (Paragraph 5-10) should be made. This check is suitable for incoming inspection. If a fault is detected in the power supply while making the performance check or during normal operation, proceed to the troubleshooting procedures (Paragraph 5-48). After troubleshooting and repair (Paragraph 5-58), perform any necessary adjustments and calibrations (Paragraph 5-60).
TM 11-6625-2965-14&P 5-8 TEST EQUIPMENT REQUIRED 5-9 Table 5-1 lists the test equipment required to perform the various procedures described in this Section. NOTE A satisfactory substitute for a differential voltmeter is to arrange a reference voltage source and null detector as shown in Figure 5-3. The reference voltage source is adjusted so that the voltage difference between the supply being measured and the reference voltage will have the required resolution for the measurement being made.
TM 11-6625-2965-14&P Table 5-1. Test Equipment Required (Continued) REQUIRED CHARACTERISTICS TYPE USE Load Resistor, HIGH range RECOMMENDED MODEL ---- Resistor 6204B, 6205B; 133 , ± 10% 15W 6206B; 120 , ±1O% 15W Resistor Value: 5 , 0.5%, 4.5 Watts, Current sampling 20ppm, 4-Terminal. Resistor Value: 6204B and 6205B, 28 , 2W (min.). 6206B, 27 , 10W (min.).
TM 11-6625-2965-14&P c. Set METER switch to highest voltage range and RANGE switch to highest voltage mode and turn on supply. d. Adjust VOLTAGE controls until front panel meter indicates exactly the maximum rated output voltage. e. Differential voltmeter should indicate maximum rated output voltage within 3%. ferential voltmeter. e . Disconnect load resistors. f.
TM 11-6625-2965-14&P i. Reading on differential voltmeter should not vary from reading recorded in Step g by m o r e than 8mVdc for Models 6204B and 6205B or 10mVdc for Model 6206B. Ripple and Noise. Definition: The residual ac voltage which is superimposed on the dc output of a regulated power supply. Ripple and noise may be specified and measured in terms of its RMS or (preferably) peak-to-peak value.
TM 11-6625-2965-14&P 5-31 Noise Spike Measurement. When a high frequency spike measurement is being made, an instrument of sufficient bandwidth must be used; an oscilloscope with a bandwidth of 20 MHz or more is adequate. Measuring noise with an instrument that has insufficient bandwidth may conceal high frequency spikes detrimental to the load.
TM 11-6625-2965-14&P cury-wetted relay contacts. Switching of larger load currents can be accomplished with mercury pool relays; with this technique fast rise times can still be obtained, but the large inertia of mercury pool relays limits the maximum repetition rate of load switching and makes the clear display of the transient recovery characteristic on an oscilloscope more difficult.
TM 11-6625-2965-14&P following formula: supply should be placed outside the oven and should have a long term stability adequate to insure that its drift will not affect the overall measurement accuracy. 5-43 To check the temperature coefficient, proceed as follows: a. Connect test setup shown in Figure 5-5. b. Turn CURRENT controls fully clockwise and adjust front panel VOLTAGE controls until the front panel voltmeter indicates 10Vdc. c.
TM 11-6625-2965-14&P ings taken at various points within the circuits. These voltages are positioned adjacent to the applicable test points (identified by encircled numbers). Component and test point designations are marked directly on the main printed wiring board. 5-47 To check the output stability, proceed as follows: a. Connect test setup shown in Figure 5-5. b. Turn CURRENT controls fully clockwise and adjust VOLTAGE controls for 40Vdc output. c.
TM 11-6625-2965-14&P Table 5-3. Overall Troubleshooting (Continued) SYMPTOM CHECKS AND PROBABLE CAUSES b. Front panel meter defective. c. Series regulator feedback loop defective. Refer to Table 5-5. Will not current limit a. Q10 open. R81 defective. High ripple a. Check operating setup for ground loops. b. If output floating, connect lµf capacitor between output and ground. Poor line regulation c. Ensure that supply is not crossing over to current limit mode under loaded conditions. a.
TM 11-6625-2965-14&P failures occur more often at the higher power levels. more useful to trace the loop from the series regulator backwards a stage at a time, since loop Table 5-4. High Output Voltage Troubleshooting STEP 1 2 3 ACTION PROBABLE CAUSE RESPONSE Check turn off of series regulator by shorting Q4 emitter to collector. a. Output voltage remains high. a. Series regulator Q7 (or Q6) shorted. b. Output voltage decreases. b. Remove short and proceed to Step 2.
TM 11-6625-2965-14&P Table 5-5. Output Voltage Troubleshooting (Continued) PROBABLE CAUSE RESPONSE 4 a. Check turn on of Q3 by shorting Q1A emitter to collector Output voltage remains low b. Output voltage increases a. Q3 open b, Check Q1A for open, QlB for short. Check R10 for short or open strap between A7 and A6 5-58 REPAIR AND REPLACEMENT teristics of selected semiconductors.
TM 11-6625-2965-l4&P Table 5-7. Checks and Adjustments After Replacement of Semiconductor Devices (Continued) REFERENCE FUNCTION CHECK Q10, CR16 (CR21) Current limit adjustment. ADJUST R81 CR22 thru CR29 Rectifier diodes Voltage across appropriate filter capacitor. VR1 Positive reference voltage +6.2V line and load regulation. R46, VR1 VR2 Negative reference voltage -6.2V line and load regulation.
TM 11-6625-2965-14&P 5-14
TM 11-6625-2965-14&P 5-69 REFERENCE CIRCUIT ADJUSTMENTS 5-70 Line Regulation. To adjust the line regulation capabilities of the instrument proceed as follows : a . Connect the differential voltmeter between +S (positive) and 31 (common). b. Connect variable voltage transformer between supply and input power source. c. Adjust line to 105Vac. d. Connect decade resistance in place of R46. e. Set range switch to high voltage mode and turn on supply. f.
TM 11-6625-2965-14&P SECTION VI REPLACEABLE PARTS 6-1 INTRODUCTION Table 6-1. 6-2 This section contains information for ordering replacement parts. Table 6-4 lists parts in alphanumeric order by reference designators and provides the following information: a. Reference Designators. Refer to Table 6-1. b. Description. Refer to Table 6-2 for abbreviations. c . Total Quantity (TQ).
TM 11-6625-2965-14&P Table 6-3.
TM 11-6625-2965-l4&P Table 6-3.
TM 11-6625-2965-14&P Table 6-3.
TABLE 6-4. REPLACEABLE PARTS REF. DESIG. TM11-6625-2965-14&P MFR. CODE hp PART NO.
TM11-6625-2965-14&P REF. DESIG. DESCRIPTION TQ MFR. PART NO. MFR. CODE hp PART NO. R34 R41 R42 R43 R44 R45 R46 R47 R49 R51 R52 R53 R54,55 R56 R57 R58 R60 R61 R72 R73 R80 R81 R87 FXD, COMP 300Ω ±5% 1/2W RXD, COMP 12KΩ ±5% 1/2W FXD, COMP 6.8KΩ ±5% 1/2W FXD, MET, FILM 470Ω ±1% 1/4W FXD, COMP 47KΩ ±5% 1/2W FXD, COMP 5.1KΩ ±5% 1/2W FXD, COMP 100KΩ ±5% 1/2W FXD, COMP 680Ω ±5% 1/2W FXD, MET. OX 3KΩ ±5% 2W FXD, COMP 20KΩ ±5% 1/2W FXD, MET. FILM 1.21KΩ ±1% 1/8W FXD, COMP 470Ω ±5% 1/2W FXD, WW 5Ω ±0.
TM11-6625-2965-14&P REF. DESIG. DESCRIPTION TQ BRACKET, TRANSF. MFG BRACKET, HEAT SINK HEAT SINK, REAR RUBBER BUMPER (FEET) PRINTED CIRCUIT BOARD RUBBER BUMPER, PRINTED CIRCUIT BOARD HEAT DISSIPATOR (Q7, Q4) MICA INSULATOR (Q7, Q4) INSULATOR, TRANSISTOR PINS (Q7, Q40 INSULATOR (Q7,Q4) END CAPS CARTON 2 2 1 4 1 3 2 2 4 4 2 1 MFR. PART NO. MB50 4072 NF-207 734 MFR. CODE hp PART NO.
TM11-6625-2965-14&P PART NUMBER - NATIONAL STOCK NUMBER CROSS REFERENCE INDEX FSCM NATIONAL STOCK NUMBER PART NUMBER FSCM NATIONAL STOCK NUMBER 58474 5940-00-738-6269 150D475X9035B2 56289 5910-00-177-4300 0150-0052 28480 5910-00-797-4909 150D475X9035B2 56289 5910-00-752-4172 0160-0153 28480 5910-00-965-9728 1510-0039 28480 5940-00-738-6269 0180-0100 28480 5910-00-752-4172 1853-0041 28480 5961-00-931-8259 0180-1836 28480 5910-00-974-6135 1853-0099 28480 5961-00-450-4689 018
TM 11-6625-2965-14&P SECTION VII CIRCUIT DIAGRAMS wiring board. b. Schematic Diagram, Figure 7-2, which illustrates the circuitry for the entire power supply. Voltages are given adjacent to test points, identified by encircled numbers on the schematic and printed wiring board. This section contains the circuit diagrams necessary for the operation and maintenance of this power supply. Included are: a.
TM ll-6625-2965-14&P APPENDIX A REFERENCES DA Pam 310-4 Index of Technical Manuals, Technical Bulletins, Supply Manuals (Types 7, 8, and 9), Supply Bulletins, and Lubrication Orders. DA Pam 310-7 US Army Equipment Index of Modification Work Orders. TM 38-750 The Army Maintenance Management System (TAMMS). TM 750-244-2 Procedures for Destruction of Electronics Materiel to Prevent Enemy Use (Electronics Command).
TM 11-6625-2965-14&P APPENDIX B COMPONENTS OF END ITEM LISTING ICOEIL 1 each Power Supply HP 6205B 6625-00-437-4861 BILL Technical Manual TM 11-6625-2965-14&P AAL N/A N/A B-1
TM 11-6625-2965-14&P APPENDIX C MAINTENANCE ALLOCATION Section 1. C -1. General This appendix provides a summary of the maintenance operations for the PP-7548/U. It authorizes categories of maintenance for specific maintenance functions on repairable items and components and the tools and equipment required to perform each function. This appendix may be used as an aid in planning maintenance operations. C-2. Maintenance Function Maintenance functions will be limited to and defined as follows: a. Inspect.
TM 11-6625-2965-14&P a. Column 1, Group Number. Column 1 lists group numbers, the purpose of which is to identify components, assemblies, subassemblies, and modules with the next higher assembly. e. Column 5, Tools and Equipment. Column 6 specifies by code, those common tool sets (not individual tools) and special tools, test and support equipment required to perform the designated function. b. Column 2, Component/Assembly.
SECTION II MAINTENANCE FOR ALLOCATION CHART POWER SUPPLY PP-7548/U (1) GROUP NUMBER 00 (2) COMPONENT/ASSEMELY Power Supply PP-7548/U (3) MAINTENANCE FUNCTION Inspect Service Test Inspect Service Test Adjust Repair Overhaul (4) MAINTENANCE CATEGORY c o F D H 0.1 0.1 0.1 (5) TOOLS AND EQPT. 2 1 (6) REMARKS A A B 0.2 0.2 3 3 c c 1.2 0.6 1.
SECTION III TOOL AND TEST EQUIPMENT REQUIREMENTS FOR POWER SUPPLY PP-7548/U TOOL OR TEST EQUIPMENT REF CODE MAINTENANCE CATEGORY NOMENCLATURE NATIONAL/NATO STOCK NUMBER 1 0 MULTIMETER AR/URM-105 6625-00-581-2036 2 0 TOOL KIT, ELECTRONIC EQUIPMENT TK-101/G 5180-00-064-5178 3 H, D TOOL KIT, ELECTRONIC EQUIPMENT TK-105/G 5180-00-610-8177 4 H, D GENERATOR, SIGNAL SG-321/U 6625-00-674-7097 5 H, D MULTIMETER AN/USM-223/U 6625-00-999-7465 6 H, D MULTIMETER, ELECTRONIC ME-260()/U 6625-00-
SECTION IV.
TM 11-6625-2965-14&P APPENDIX D MANUAL BACKDATING CHANGES Manual backdating changes describe changes necessary to adapt this manual to earlier instruments. T O adapt the manual to serial numbers prior to 7L2301 inspect the following table for your serial number and then make the appropriate changes. For serial numbers 7L4450 and up check for inclusion of change sheet. CHANGE 1: In the replaceable parts table, make the following changes: Delete Q10. Delete R51.
TM 11-6625-2965-14&P Option 11, Overvoltage Protection “Crowbar” DESCRIPTION: This option is installed in DC Power Supplies, 6200B, 6201B, 6202B, 6203B, 6204B, and 6206B, and tested at the factory. It consists of a printed circuit board, screwdriver-type front panel potentiometer, and six wires that are soldered to the main power supply board. The crowbar monitors the output voltage of the power supply and fires an SCR that effectively shorts the output when it exceeds the preset trip voltage.
TM11-6625-2965-14&P TABLE A-1. REPLACEABLE PARTS REF. DESIG. DESCRIPTION TQ MFR. PART NO. MFR. CODE hp PART NO. RS C1 C2 FXD, ELECT 1µF 50VDC FXD, MICA 510µF 500VDC 2 2 30D105G050BA2 RCM15E511J 56289 04062 0180-0108 0140-0047 1 1 CR1-CR3 CR4 RECT. SI. 200MA 200PRV SCR 7.4A 100PRV 6 2 1N485B C20B 93332 03508 1901-0033 1884-0032 6 2 Q1,2 SS NPN SI. 4 2N3417 03508 1854-0087 4 R1 R2 R3 R4 R5 R6 R7 R8 FXD, FXD, FXD, FXD, VAR.
TM 11-6625-2965-14&P Figure A-1. Models 6200B, 6204B, and 6205B* Overvoltage Protection “Crowbar” *For Model 6205B the above circuit is duplicated on each half of the assembled board, 06205-60021.
MANUAL CHANGES ITM 11-6625-2965-14&P Model 6205B DC Power Supply Manual HP Part No. 06205-90002 Make all corrections in the manual according to errata below, then check the following table for your power supply serial number and enter any listed change(s) in the manual. SERIAL Prefix ALL 7L 7L lC 1140A Number 5451 5901 6201 6301 - 5900 - 6200 - 6300 - up MAKE CHANGE S The primary wiring of the unit is now as shown below.
Manual Changes/Model 6205B TM 11-6625-2965-14&P HP PART NO. DESCRIPTION STANDARD Front Panel, Lettered 06205-00005 OPTION A85 06205-60004 Chassis, Right Side 5060-7956 5060-6118 Chassis, Left Side 5060-7955 5060-6119 Cover, Top 5000-9424 5000-6061 Rack Kit (accessory) 14523A 14523A-A85 06205-60002 06205-60005 Heatsink ERRATA: In parts list, change HP Part No. of rubber bumper (qty. 4) to 0403-0002. In Figure 5-4, change Rx value listed for Model 6206B to 3 ohms.
TM 11-6625-2965-14&P Figure 7-1. Component Location Diagram Figure 7-2.
By Order of the Secretary of the Army: E. C. MEYER Official: J. C.
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